JP2016171041A - Method of manufacturing aluminum wire with terminal - Google Patents

Method of manufacturing aluminum wire with terminal Download PDF

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JP2016171041A
JP2016171041A JP2015051363A JP2015051363A JP2016171041A JP 2016171041 A JP2016171041 A JP 2016171041A JP 2015051363 A JP2015051363 A JP 2015051363A JP 2015051363 A JP2015051363 A JP 2015051363A JP 2016171041 A JP2016171041 A JP 2016171041A
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solder
coating
solder coating
aluminum
electric wire
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敏明 葛西
Toshiaki Kasai
敏明 葛西
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Fujikura Ltd
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Fujikura Ltd
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Abstract

PROBLEM TO BE SOLVED: To surely prevent galvanic corrosion.SOLUTION: A cut line is marked at a separation position of insulation coating 21 of an aluminum wire 20 (FIG. 1(a)), insulation coating 21a is peeled off to expose a core wire portion 23 (FIG. 1(b)), solder coating 25 is formed on the exposed core wire portion 23 (FIG. 1(c)), the aluminum wire 20 having the solder coating 25 and a connector terminal 30 are aligned with each other (FIG. 1(d)), the aluminum wire 20 having the solder coating 25 and the connector terminal 30 are connected to each other in a state where the tip of the solder coating 25 is exposed (FIG. 1(e)), and laser irradiation is performed on the tip of the solder coating 25 (FIG. 1(f)).SELECTED DRAWING: Figure 1

Description

本発明は、端子付アルミ電線の製造方法に関する。   The present invention relates to a method for manufacturing a terminal-attached aluminum electric wire.

自動車用電線の軽量化を目的に，導体に軽量のアルミニウムを採用したアルミ電線が 注目されている。しかし、アルミ電線を銅製圧着端子と接続した場合、接触部に水分が介在すると、アルミニウムと銅との間に電位差が生じて腐食（ガルバニック腐食）が発生することが知られている。   Aluminum wires that use lightweight aluminum as the conductor are attracting attention for the purpose of reducing the weight of automotive wires. However, when an aluminum electric wire is connected to a copper crimp terminal, it is known that if moisture is present in the contact portion, a potential difference is generated between aluminum and copper, causing corrosion (galvanic corrosion).

このガルバニック腐食を防止するため、アルミ電線の先端部を露出させた導体部分に半田コーティングした後、端子を圧着する方法がある。この方法によれば、端子の銅部分とアルミ電線のアルミ部分が接触することがなく、かつ露出するアルミ電線先端部が水滴等の水分に晒されることを防止できる（特許文献１参照）。   In order to prevent this galvanic corrosion, there is a method in which the terminal is crimped after solder coating is applied to the exposed conductor portion of the aluminum wire. According to this method, the copper portion of the terminal and the aluminum portion of the aluminum electric wire do not come into contact with each other, and the exposed end portion of the aluminum electric wire can be prevented from being exposed to moisture such as water droplets (see Patent Document 1).

しかしながら、上記の方法では、アルミ電線の先端部表面に被覆させた半田を端子のワイヤバレル片によって圧着するため割れが生じることがあり、この割れ目からアルミ電線の先端部に水分が侵入し、腐食が発生してしまうという問題点があった。   However, in the above method, the solder coated on the surface of the tip of the aluminum electric wire is crimped by the wire barrel piece of the terminal, so that cracks may occur. There was a problem that would occur.

これに対して、導体部分に被覆する半田が圧着力によって割れる程度の強さに圧着する強圧着部と、この強圧着部の先端側で半田が圧着力によって割れが生じない強さに圧着する弱圧着部とを形成するように導体圧着部を加締め、導体部と圧着端子とを接続する圧着端子付きアルミ電線も提案されている（特許文献２参照）。   On the other hand, a strong pressure-bonding portion where the solder covering the conductor portion is crimped to such a strength that it can be broken by the pressure-bonding force, and the solder is pressure-bonded at the tip side of the strong pressure-bonding portion to a strength that does not cause cracking due to the pressure-bonding force. There has also been proposed an aluminum electric wire with a crimp terminal for crimping a conductor crimp portion so as to form a weak crimp portion and connecting the conductor portion and the crimp terminal (see Patent Document 2).

しかしながら、上記圧着端子付きアルミ電線においても、強圧着部に生じた亀裂が弱圧着部まで成長する可能性があり、ガルバニック腐食を防止する方法としては不十分であった。   However, even in the aluminum electric wire with a crimp terminal, a crack generated in the strong crimp portion may grow to the weak crimp portion, which is insufficient as a method for preventing galvanic corrosion.

ＷＯ２０１１／０９６５２７Ａ１WO2011 / 096527A1 特開２０１４−０２６９０５号公報JP 2014-026905 A

本発明は、上記課題に鑑みてなされたもので、確実にガルバニック腐食を防止することができる端子付アルミ電線の製造方法を提供することを目的とする。   This invention is made | formed in view of the said subject, and it aims at providing the manufacturing method of the aluminum electric wire with a terminal which can prevent a galvanic corrosion reliably.

本発明に係る端子付アルミ電線の製造方法は、アルミニウム又はアルミニウム合金製の芯線及びその外周に設けられた絶縁被覆を有するアルミ電線の先端部の前記絶縁被覆を剥離して芯線部分を露出させる剥離工程と、露出させた芯線部分の表面に半田被覆を形成する半田被覆工程と、前記アルミ電線と電気的に接続されるバレル部を有するコネクタ端子の前記バレル部と前記半田被覆が形成された導体部分とを、前記導体部分の先端部を露出させつつ圧着接続する接続工程と、前記露出させた導体部分に熱を加えるリフロー工程とを備えることを特徴とする。   The method for producing an aluminum electric wire with a terminal according to the present invention includes an aluminum or aluminum alloy core wire and an exfoliation for exfoliating the insulating coating at the tip of the aluminum electric wire having an insulating coating provided on the outer periphery thereof to expose the core wire portion. A solder coating step of forming a solder coating on the surface of the exposed core wire portion; a connector terminal having a barrel portion electrically connected to the aluminum electric wire; and a conductor on which the solder coating is formed And a reflow step of applying heat to the exposed conductor portion.

本発明に係る端子付アルミ電線の製造方法によれば、仮に半田被覆に亀裂が発生していても、前記リフロー工程によってこの亀裂を修復し、亀裂の成長を抑えることができるため、アルミ部分が露出することを防止することができる。   According to the manufacturing method of the terminal-equipped aluminum electric wire according to the present invention, even if a crack is generated in the solder coating, the crack can be repaired by the reflow process and the growth of the crack can be suppressed. It is possible to prevent exposure.

また、前記リフロー工程は、レーザを照射し、前記半田被覆を溶融することによって行うことが好ましい。レーザを照射することにより、仮に半田被覆に亀裂が発生していても、この亀裂を確実に修復し、亀裂の成長を抑えることができる。   The reflow process is preferably performed by irradiating a laser to melt the solder coating. By irradiating the laser, even if a crack is generated in the solder coating, the crack can be reliably repaired and the growth of the crack can be suppressed.

本発明によれば、確実にガルバニック腐食を防止することができる。   According to the present invention, galvanic corrosion can be reliably prevented.

本発明の一実施形態に係る端子付アルミ電線の製造方法を示す側面図であり、（ａ）はアルミ電線の絶縁被覆の分離位置に切り目を入れた状態、（ｂ）は分離位置から絶縁被覆を剥いで芯線を露出した状態、（ｃ）は露出した芯線に半田被覆を形成した状態、（ｄ）は芯線に半田被覆を形成したアルミ電線とコネクタ端子とを位置合わせした状態、（ｅ）は芯線に半田被覆を形成したアルミ電線とコネクタ端子とを接続した状態、（ｆ）は半田被覆先端部にレーザ照射を行った状態である。BRIEF DESCRIPTION OF THE DRAWINGS It is a side view which shows the manufacturing method of the aluminum electric wire with a terminal which concerns on one Embodiment of this invention, (a) is the state which cut | disconnected the isolation | separation position of the insulation coating of the aluminum electric wire, (b) is insulation coating from the isolation | separation position. (C) is a state in which a solder coating is formed on the exposed core wire, (d) is a state in which an aluminum electric wire having a solder coating on the core wire and a connector terminal are aligned, (e) Is a state in which an aluminum electric wire having a solder coating formed on the core wire and a connector terminal are connected, and (f) is a state in which the tip of the solder coating is irradiated with laser.

以下、添付の図面を参照して、本発明の実施形態に係る端子付アルミ電線の製造方法について詳細に説明する。   Hereinafter, with reference to an accompanying drawing, a manufacturing method of an aluminum electric wire with a terminal concerning an embodiment of the present invention is explained in detail.

本実施形態に係る端子付アルミ電線の製造方法は、アルミ電線の絶縁被覆を剥離して芯線を露出させる剥離工程と、露出した芯線の表面に半田被覆を形成する半田被覆工程と、圧着によりアルミ電線とコネクタ端子とを接続する接続工程と、半田被覆の先端部分に熱を加えるリフロー工程とを備えている。以下、各工程について詳しく説明する。   The manufacturing method of an aluminum electric wire with a terminal according to the present embodiment includes a peeling step of peeling the insulating coating of the aluminum electric wire to expose the core wire, a solder coating step of forming a solder coating on the surface of the exposed core wire, and aluminum by pressure bonding. A connection step for connecting the electric wire and the connector terminal, and a reflow step for applying heat to the tip of the solder coating. Hereinafter, each step will be described in detail.

（剥離工程）
アルミ電線２０は、複数本からなるアルミニウムまたはアルミニウム合金製の素線を撚り合せた撚り線によって芯線が形成され、この芯線の回りが塩化ビニル等の合成樹脂製の絶縁被覆２１で覆われた構造となっている。このアルミ電線２０の絶縁被覆２１の分離位置に切れ目を入れ、絶縁被覆２１ａと絶縁被覆２１ｂとに分離し（図１（ａ））、絶縁被覆２１ａを剥離して芯線２３を露出させる（図１（ｂ））。 (Peeling process)
The aluminum electric wire 20 has a structure in which a core wire is formed by a stranded wire obtained by twisting a plurality of aluminum or aluminum alloy wires, and the periphery of the core wire is covered with an insulating coating 21 made of a synthetic resin such as vinyl chloride. It has become. A cut is made at the separation position of the insulation coating 21 of the aluminum electric wire 20, and the insulation coating 21a and the insulation coating 21b are separated (FIG. 1A), and the insulation coating 21a is peeled to expose the core wire 23 (FIG. 1). (B)).

（半田被覆工程）
次に、露出された芯線２３の外周に半田を塗布し、半田被覆２５を形成する（図１（ｃ））。半田被覆２５は、コネクタ端子３０とイオン化傾向が近い金属を主成分とする半田から形成される。半田の種類としては、鉛フリー半田が好適であり、具体的には、Ｓｎ−Ａｇ−Ｃｕ（錫−銀−銅）系、Ｓｎ−Ｃｕ（錫−銅）系、Ｓｎ−Ｚｎ（錫−亜鉛）系などを用いることができる。本実施形態では、成分割合が、例えば、Ｓｎ：約８０％、Ｚｎ：約２０％のものを適用することができる。この成分割合の半田は、アルミニウムに対する濡れやすさに優れている。半田被覆２５の形成方法としては、半田の含浸、具体的には、露出された芯線２３の部分を、半田槽等に貯留された溶融半田に浸漬するフロー方式によって行うことができる。このようにアルミ電線２０の芯線２３が半田被覆２５によって覆われることにより、露出された導体部が防水される。 (Solder coating process)
Next, solder is applied to the outer periphery of the exposed core wire 23 to form a solder coating 25 (FIG. 1C). The solder coating 25 is made of solder whose main component is a metal having a tendency to ionize with the connector terminal 30. As a kind of solder, lead-free solder is suitable, and specifically, Sn-Ag-Cu (tin-silver-copper), Sn-Cu (tin-copper), Sn-Zn (tin-zinc). ) System can be used. In the present embodiment, for example, a component ratio of Sn: about 80% and Zn: about 20% can be applied. Solder with this component ratio is excellent in wettability to aluminum. The solder coating 25 can be formed by a flow method in which solder is impregnated, specifically, the exposed portion of the core wire 23 is immersed in molten solder stored in a solder bath or the like. Thus, the exposed conductor part is waterproofed by covering the core wire 23 of the aluminum electric wire 20 with the solder coating 25.

（接続工程）
次に、半田被覆された導体部にコネクタ端子３０を圧着することで、導体部とコネクタ端子３０との間の電気的接続が取られる。
コネクタ端子３０は、銅合金等の導電性金属製の板材をプレス成形や折り曲げ成形を行うことによって形成されている。このコネクタ端子３０の先方には、相手方端子と電気的に接続される略角筒形の接続部３１が設けられ、接続部３１の後方には、ワイヤバレル３３が設けられている。ワイヤバレル３３は、左右一対の幅広のバレル片が、コネクタ端子３０の底板の左右の側縁から互いに対向するようにして立ち上がり形成されている（図１（ｄ）参照）。このワイヤバレル３３は、半田被覆２５にかしめ圧着され、両バレル片の突出端を重ね合わせつつ半田被覆２５の外周を左右両側から抱き込むようにしてかしめられる。このようにして、半田被覆２５が形成されたアルミ電線２０の端末にコネクタ端子３０が圧着接続され、芯線２３とコネクタ端子３０が半田被覆２５を通じて導通可能に接続される。ここで、半田被覆２５の先端部分は目視検査のため、数ｍｍ程度ワイヤバレル３３から露出されている（図１（ｅ）参照）。 (Connection process)
Next, the connector terminal 30 is pressure-bonded to the solder-covered conductor portion, whereby electrical connection between the conductor portion and the connector terminal 30 is taken.
The connector terminal 30 is formed by press-molding or bending a conductive metal plate material such as a copper alloy. At the tip of the connector terminal 30, there is provided a connection portion 31 having a substantially rectangular tube shape that is electrically connected to the counterpart terminal, and a wire barrel 33 is provided behind the connection portion 31. The wire barrel 33 is formed so that a pair of left and right wide barrel pieces face each other from the left and right side edges of the bottom plate of the connector terminal 30 (see FIG. 1D). The wire barrel 33 is caulked and crimped to the solder coating 25, and is caulked so as to embrace the outer periphery of the solder coating 25 from both the left and right sides while overlapping the protruding ends of both barrel pieces. In this manner, the connector terminal 30 is crimped to the end of the aluminum electric wire 20 on which the solder coating 25 is formed, and the core wire 23 and the connector terminal 30 are connected through the solder coating 25 so as to be conductive. Here, the tip portion of the solder coating 25 is exposed from the wire barrel 33 by a few millimeters for visual inspection (see FIG. 1E).

（リフロー工程）
最後に、ワイヤバレル３３から露出した半田被覆２５の部分に熱を加えてリフローし、半田を再溶融する。熱を加える方法としては、図１（ｆ）に示すように、レーザ照射が好適である。レーザ照射は、強度が２０〜５０Ｗ程度、好ましくは３０Ｗ、時間は１〜５秒程度、好ましくは２秒の条件で行うことができる。このリフロー工程によって、仮に半田被覆２５に亀裂が発生していても、この亀裂を修復し、亀裂の成長を抑えることができるため、アルミ部分が露出することを防止することができる。
この結果、防食剤を使用することなくアルミ電線２０とコネクタ端子３０との接続部分の腐食を確実に防止できる端子付アルミ電線１０を提供することができる。 (Reflow process)
Finally, heat is applied to the portion of the solder coating 25 exposed from the wire barrel 33 and reflowed to remelt the solder. As a method for applying heat, laser irradiation is suitable as shown in FIG. Laser irradiation can be performed under conditions of an intensity of about 20 to 50 W, preferably 30 W, and a time of about 1 to 5 seconds, preferably 2 seconds. Even if a crack is generated in the solder coating 25 by this reflow process, the crack can be repaired and the growth of the crack can be suppressed, so that the aluminum portion can be prevented from being exposed.
As a result, it is possible to provide the terminal-equipped aluminum electric wire 10 that can reliably prevent corrosion of the connection portion between the aluminum electric wire 20 and the connector terminal 30 without using a corrosion inhibitor.

また、レーザを用いたリフローによる修復を行うため、従来のように強圧着部と弱圧着部の形成による半田亀裂防止を行う必要がなく、圧着部分の繊細な位置合わせの調整が不要になる。   In addition, since repair is performed by reflow using a laser, it is not necessary to prevent solder cracks by forming a strong pressure-bonding portion and a weak pressure-bonding portion as in the prior art, and delicate adjustment of the pressure-bonded portion is not necessary.

以上のことにより、本実施形態に係る端子付アルミ電線の製造方法によれば、確実にガルバニック腐食を防止することが可能となる。   As described above, according to the method for manufacturing an aluminum electric wire with a terminal according to the present embodiment, galvanic corrosion can be reliably prevented.

［その他の実施の形態］
以上、本発明のいくつかの実施形態を説明したが、これらの実施形態は、例として提示したものであり、発明の範囲を限定することは意図していない。これら実施形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略、置き換え、変更を行うことができる。これら実施形態やその変形は、発明の範囲や要旨に含まれると同様に、特許請求の範囲に記載された発明とその均等の範囲に含まれるものである。例えば、上記実施形態では、リフロー工程として、レーザ照射による加熱を用いたが、エアーやＮ２ガスなどを加熱してノズルから噴出させるホットエアー法やパルス電流を流すことで発生したジュール熱を用いるパルスヒート法のような部分加熱方法を用いて行うこともできる。 [Other embodiments]
As mentioned above, although some embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are also included in the invention described in the claims and the equivalents thereof. For example, in the above embodiment, heating by laser irradiation is used as the reflow process. However, a hot air method in which air or N 2 gas is heated and ejected from the nozzle or Joule heat generated by flowing a pulse current is used. A partial heating method such as a pulse heat method can also be used.

１０・・・端子付アルミ電線、
２０・・・アルミ電線
２１・・・絶縁被覆
２１ａ、２１ｂ・・・絶縁被覆
２３・・・芯線
２５・・・半田被覆
３０・・・コネクタ端子
３１・・・接続部
３３・・・ワイヤバレル
10 ... Aluminum wire with terminal,
DESCRIPTION OF SYMBOLS 20 ... Aluminum electric wire 21 ... Insulation coating 21a, 21b ... Insulation coating 23 ... Core wire 25 ... Solder coating 30 ... Connector terminal 31 ... Connection part 33 ... Wire barrel

Claims (2)

アルミニウム又はアルミニウム合金製の芯線及びその外周に設けられた絶縁被覆を有するアルミ電線の先端部の前記絶縁被覆を剥離して芯線部分を露出させる剥離工程と、
露出させた芯線部分の表面に半田被覆を形成する半田被覆工程と、
前記アルミ電線と電気的に接続されるバレル部を有するコネクタ端子の前記バレル部と前記半田被覆が形成された導体部分とを、前記導体部分の先端部を露出させつつ圧着接続する接続工程と、
前記露出させた導体部分に熱を加えるリフロー工程と
を備えることを特徴とする端子付アルミ電線の製造方法。 A peeling step of peeling the insulating coating at the tip of the aluminum electric wire having an aluminum or aluminum alloy core wire and an insulating coating provided on the outer periphery thereof to expose the core wire portion;
A solder coating step of forming a solder coating on the surface of the exposed core wire part;
A connecting step of crimping and connecting the barrel portion of the connector terminal having a barrel portion electrically connected to the aluminum electric wire and the conductor portion on which the solder coating is formed, while exposing a tip portion of the conductor portion;
And a reflow step of applying heat to the exposed conductor portion. 前記リフロー工程は、レーザを照射し、前記半田被覆を溶融することによって行うことを特徴とする請求項１記載の端子付アルミ電線の製造方法。   2. The method of manufacturing an aluminum electric wire with a terminal according to claim 1, wherein the reflow step is performed by irradiating a laser and melting the solder coating.
JP2015051363A 2015-03-13 2015-03-13 Method of manufacturing aluminum wire with terminal Pending JP2016171041A (en)

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Publication number Priority date Publication date Assignee Title
CN107196173A (en) * 2017-06-21 2017-09-22 芜湖安普机器人产业技术研究院有限公司 A kind of plug-in type triangle wire harness production equipment
JP2019079734A (en) * 2017-10-26 2019-05-23 矢崎総業株式会社 Aluminum wire crimping method and aluminum wire crimping structure
JP2020009641A (en) * 2018-07-09 2020-01-16 矢崎総業株式会社 Electric wire with terminal
CN113433133A (en) * 2020-03-23 2021-09-24 株式会社东芝 Pressure welding judging method
JP7357446B2 (en) 2018-12-19 2023-10-06 矢崎総業株式会社 Electric wire with terminal and its manufacturing method

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JP2010020980A (en) * 2008-07-09 2010-01-28 Autonetworks Technologies Ltd Electric wire with terminal metal fitting, and manufacturing method thereof
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Publication number Priority date Publication date Assignee Title
CN107196173A (en) * 2017-06-21 2017-09-22 芜湖安普机器人产业技术研究院有限公司 A kind of plug-in type triangle wire harness production equipment
JP2019079734A (en) * 2017-10-26 2019-05-23 矢崎総業株式会社 Aluminum wire crimping method and aluminum wire crimping structure
JP7129770B2 (en) 2017-10-26 2022-09-02 矢崎総業株式会社 Aluminum wire crimping method and aluminum wire crimping structure
JP2020009641A (en) * 2018-07-09 2020-01-16 矢崎総業株式会社 Electric wire with terminal
JP7357446B2 (en) 2018-12-19 2023-10-06 矢崎総業株式会社 Electric wire with terminal and its manufacturing method
CN113433133A (en) * 2020-03-23 2021-09-24 株式会社东芝 Pressure welding judging method
JP2021150230A (en) * 2020-03-23 2021-09-27 株式会社東芝 Crimping determination method

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